Method of forming a metal fiberglass interface

• US 4,599,257 A
• Filed: 03/06/1984
• Issued: 07/08/1986
• Est. Priority Date: 03/06/1984
• Status: Expired due to Fees

• Current Assignee: Thomas Wozniak
• Original Assignee: Thomas Wozniak
• Inventors: Nutt, Charles O.
• Primary Examiner(s): Weston, Caleb
• Application Number:
  US06/586,623
• Time in Patent Office: 854 Days
• Field of Search: 156/196, 156/242, 156/245, 156/252, 156/253, 29/469.5, 29/521, 428/131, 428/137, 428/174
• US Class Current: 428/131
• CPC Class Codes: B32B 15/14 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2419/06 Roofs, roof membranes
• CPC Class Codes: B32B 37/28 involving assembly of non-flat intermediate products which are flattened at a later step, e.g. tubes
• CPC Class Codes: E04D 13/155 retaining the roof sheathing
• CPC Class Codes: E04D 3/362 by locking the edge of one slab or sheet within the profiled marginal portion of the adjacent slab or sheet, e.g. using separate connecting elements
• CPC Class Codes: E04D 3/38 Devices for sealing spaces or joints between roof-covering elements E04D3/36 takes precedence; sealing joints not restricted to roof-covering elements E04B1/68
• CPC Class Codes: Y10T 156/1002 with permanent bending or reshaping or surface deformation of self sustaining lamina
• CPC Class Codes: Y10T 156/1056 Perforating lamina
• CPC Class Codes: Y10T 156/1057 Subsequent to assembly of laminae
• CPC Class Codes: Y10T 29/49906 Metal deforming with nonmetallic bonding
• CPC Class Codes: Y10T 29/49936 Surface interlocking
• CPC Class Codes: Y10T 428/24273 including aperture
• CPC Class Codes: Y10T 428/24322 Composite web or sheet
• CPC Class Codes: Y10T 428/24628 Nonplanar uniform thickness material

Abstract

A method of creating a waterproof metal/fiberglass interface for a composite structural component, comprising the steps of: bending one end (13) of an apertured metal sheet into a U-shaped channel (24); filling the channel (24) with a resin impregnated fabric (23); and then laying a gel coat adjacent the metal, a calking bead at the juncture of the metal and gel coat, and an overcoat of fiberglass that will penetrate the apertures (14) in the metal and the fabric (23).

Claims

1. A method for forming a metal/fiberglass interface between a sheet of metal and a layer of fiberglass comprising the steps of:

a) providing a plurality of spaced apertures along one edge of the sheet of metal to form an apertured portion;

b) bending the apertured portion of the sheet of metal to form a U-shaped channel;

c) placing the sheet of metal on a mold surface;

d) masking the apertured portion of the U-shaped channel;

e) applying a gel coat to the mold surface, wherein the gel coat contacts the exterior bend of the U-shaped channel;

f) removing the masking from the apertured portion of the U-shaped channel; and

g) applying a layer of fiberglass over the gel coat and the apertured portion of the sheet metal, wherein the layer of fiberglass covers a substantial portion of the metal sheet, and flows through the apertures to fill the U-shaped channel.

2. A method as in claim 1 comprising an intermediate step (h) between steps (f) and (g) wherein step h) involves depositing a bead of incurable calk at the juncture of the gel coat and the exterior bend of the U-shaped channel member.

3. A finished product produced by the method of claim 1.

4. The method of claim 1;

wherein the metal sheet comprises a standing seam for a roof panel assembly.

5. A method for forming a metal/fiberglass interface between a sheet of metal and a layer of fiberglass comprising the steps of:

(a) providing a plurality of spaced apertures along one edge of the sheet of metal to form an apertured portion;

(b) bending the apertured portion of the sheet of metal to form a U-shaped channel, wherein the apertured portion of the sheet of metal forms one of the legs of the U-shaped channel;

(c) placing the sheet of metal on a mold surface;

(d) masking the apertured leg of the U-shaped channel;

(e) applying a gel coat to the mold surface, wherein the gel coat contacts the exterior bend of the U-shaped channel;

(f) depositing a bead of uncurable calk at the juncture of the gel coat and the exterior bend of the U-shaped channel member;

(g) removing the masking from the apertured leg of the U-shaped channel;

(h) inserting a resin impregnated strip of fabric into the channel, in order to fill the channel with fabric; and

(i) applying a layer of fiberglass over the gel coat and the apertured portion of the sheet metal, wherein the layer of fiberglass covers a substantial portion of the metal sheet and penetrates the resin impregnated fabric that fills the U-shaped channel.

6. A method as in claim 5 wherein steps f) thru h) are interchangeable.

7. A finished product produced by the method of claim 5.

8. The method of claim 5;

wherein the metal sheet comprises a standing seam for a roof panel assembly.